A method for making a float adapter for an electrical connector that includes a conductive shell that has opposite first and second ends, and at least one insulator received in the conductive shell. The at least one insulator has an engagement end and an interface end opposite the engagement end. The interface end has a lead-in tip portion that extends outside of one of the first and second ends of the shell. The at least one insulator has an inner bore for receiving an inner contact. A retaining sleeve is disposed around the conductive shell, the retaining sleeve having an engagement member for engaging the at least one insulator.
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1. Method of manufacturing of a float adapter, comprising the steps of:
stamping a piece from a metal sheet;
rolling the stamped piece into a cylindrical body to form a conductive shell;
providing at least one insulator, the at least one insulator having an engagement end, an interface end opposite the engagement member, and an inner bore extending through the engagement end and the interface end;
inserting one end of an inner contact into the inner bore of the at least one insulator;
inserting the at least one insulator and the inner contact into the conductive shell through one end of the conductive shell; and
coupling a retaining sleeve around the conductive shell such that the retaining sleeve engages the at least one insulator.
2. A method of
the retaining sleeve includes an engagement member corresponding to an engagement member of the at least one insulator.
3. A method of
the engagement member of the retaining sleeve is a tab and the engagement member of the at least one insulator is a groove; and
the conductive shell includes a slot for receiving the tab.
4. A method of
prior to rolling the stamped piece, cutting slots into ends of the stamped piece to form fingers.
5. A method of
prior to rolling the stamped piece, impressing a groove into the ends of the stamped piece.
6. A method of
prior to rolling the stamped piece, cutting at least one slot into stamped piece.
7. A method of
inserting the other end of the inner contact into a second insulator.
8. A method of
coupling the retaining sleeve with the second insulator.
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This application is a divisional of application Ser. No. 15/044,769 filed Feb. 16, 2016, which is a continuation-in-part of application Ser. No. 14/594,585, (now U.S. Pat. No. 9,356,374) filed Jan. 12, 2015, which is a continuation-in-part of application Ser. No. 13/737,375 (now U.S. Pat. No. 9,039,433), filed Jan. 9, 2013, the subject matter of each of which is incorporated by reference herein.
The present invention relates to a float adapter for an electrical connector, particularly for board-to-board connections, and a method for making the same.
A radio frequency (RF) connector is an electrical connector designed to work at radio frequencies in the multi-megahertz range. Typically, RF connectors are used in a variety of applications such as wireless telecommunications applications, including WiFi, PCS, radio, computer networks, test instruments, and antenna devices. In some instances, a number of individual connectors are ganged together into a single, larger connector housing for electrically and physically connecting two or more printed circuit boards.
One example of an RF connector interface is the sub-miniature push-on (SMP) interface. SMP is commonly used in miniaturized high frequency coaxial modules and is offered in both push-on and snap-on mating styles and is often used for PC board-to-board interconnects. For these applications, the conventional SMP interface utilizes a male connector on each of the PC boards and a female-to-female adapter mounted in between to complete the connection. One problem with conventional RF connectors is that such connectors typically do not have the flexibility to customize the degree of axial or radial float between connectors.
Another problem associated with conventional RF connectors is that the density of individual connectors is limited by the shape and design of the adapter. As RF connector applications have begun to require a greater number of individual connections between components, RF connectors using conventional designs have necessarily increased in size to accommodate this. Larger connectors require more physical space in order to provide the necessary contacts, which make the connectors less applicable to high density systems requiring smaller connectors and more expensive to produce.
Accordingly, there is a need for an electrical connector, such an RF connector, with improved axial and radial float while also having a smaller profile.
Accordingly, the present invention provides a float adapter for an electrical connector that includes a conductive shell that has opposite first and second ends, and at least one insulator received in the conductive shell. The at least one insulator has an engagement end and an interface end opposite the engagement end. The interface end has a lead-in tip portion that extends outside of one of the first and second ends of the shell. The at least one insulator has an inner bore for receiving an inner contact. A retaining sleeve is disposed around the conductive shell, the retaining sleeve having an engagement member for engaging the at least one insulator.
The present invention may also provide an electrical connector assembly, that includes a first connector that has at least one contact extending into at least one cavity, a second connector that has at least one contact extending into at least one cavity; and at least one float adapter coupling the first and second connectors. The float adapter includes a conductive shell that has opposite first and second ends and first and second insulators received in the conductive shell. Each of the first and second insulators have an engagement end and an interface end opposite the engagement end. The interface end has a lead-in tip portion extending outside of the first and second ends of the shell, respectively. Each of the first and second insulators has an inner bore. An inner contact is received in the inner bore of both of the first and second insulators. A retaining sleeve is disposed around the conductive shell that has first and second engagement members for engaging the first and second insulators, respectively.
The present invention may further provide a method of manufacturing of a float adapter, comprising the steps of stamping a piece from a metal sheet; rolling the stamped piece into a cylindrical body to form a conductive shell; providing at least one insulator, the at least one insulator having an engagement end, an interface end opposite the engagement member, and an inner bore extending through the engagement end and the interface end; inserting one end of an inner contact into the inner bore of the at least one insulator; inserting the at least one insulator and the inner contact into the conductive shell through one end of the conductive shell; and coupling a retaining sleeve around the conductive shell such that the retaining sleeve engages the at least one insulator.
Other objects, advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention.
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
Several preferred embodiments of the invention are described for illustrative purposes, it being understood that the invention may be embodied in other forms not specifically shown in the drawings.
The subject matter described herein relates an electrical connector, such as a radio frequency (RF) connector, that is applicable to high density gang-mate printed circuit board PCB-to-PCB solutions in either high float or low float configurations, where float is the tolerance of physical movement or misalignment compensation of the connectors once mated in a fixed position. More specifically, the present invention provides a connector that may have a protruding insulator from a plug interface thereof that has a narrowing shape, such as a pyramid or “dart” shaped lead-in geometry at its tip. Additionally, the present invention includes a bi-gender bullet that has a plug interface on one end and a receptacle interface on the opposite end for providing modular add-on float capability between connectors.
Regarding the first aspect of the present invention, a dart shaped insulating material protrudes from an outer metal housing and protects a recessed, inner contact to facilitate gathering. As used herein, gathering is the process of aligning a plug and a receptacle during the mating process. For example, gathering may include inserting the tip of the plug into a cone (or other) shaped receptacle of the receptacle. Selection of specific shapes of both the tip of the plug and the receptacle aids in aligning the tip to the center of the receptacle through physical contact with the cone and redirection of the insertion forces to a desired position. The present invention is an improvement over the prior art at least in that, by using the protruding insulator for gathering, the geometry of the plug interface required to gather shrinks, and thus a smaller lead-in geometry is possible on the mating receptacle interface.
Another advantage of the present invention is that the inverted pyramid gathering feature on the receptacle insulator aids with blind mate gathering (plugging the connector into a board without human intervention) of the receptacle center contact pin. Yet another advantage of the present invention is that the insulator on the plug provides closed entry protection for female contact on the plug. In other words, it may prevent unwanted contact between the inner contact portion and other portions of the plug (e.g., the outer casing) or portions of the mating receptacle interface.
Regarding the second aspect, the present invention is an improvement over the prior art at least in that the bi-gender bullet allows for increasing the amount of mechanical float between a male and female connector assembly simply by adding the bi-gender bullet between the connectors. Low-float configurations are made by directly mating a male and a female connector without using a bullet therebetween. Thus, the bi-gender bullet of the present invention allows for selecting between low-float and high-float configurations without requiring a change in the gender of either of the connectors. This modular design allows for simpler, cheaper, and more flexible connector products that may use either high float or low float configurations. In contrast, most conventional designs require that the mating connectors have the same interface for high-float configurations.
A bullet according to the present invention may be retained on the standard plug interface with a plastic carrier housing that snaps onto the plug housing. The snap-on feature on the plug housing converts any non-bulleted solution to one having one or more bullets added for additional radial float between connectors.
Turning now to
As used herein, the term “contact sub-assembly” refers to an individual connector that includes at least a contact portion, but may also include an insulator portion and a ground body portion, for physically and electrically interfacing with another connector or a PCB. As shown in
The plug assembly 100 preferably includes two rows of contact sub-assemblies 102A and 102B. It is appreciated, however, that other configurations of the contact sub-assemblies may be used without departing from the scope of the subject matter described herein. For example, a single row, three or more rows, and staggered rows of the contact sub-assemblies may be located in the housing 210. The contact sub-assembly 102A may include a contact 104A comprising a conductive material, such as copper, hardened beryllium copper, gold- or nickel-plating, and the like for carrying electrical signals. The contact 104A may be bent at a right angle in the configuration shown; however, it is appreciated that other configurations, such as straight, may also be used without departing from the scope of the subject matter described herein. The contact 104A is preferably enclosed within an outer insulator 106A that has two parts, where a first part is configured to encase the portion of the contact 104A which is bent at the right angle, and a second part which is detachable from the first part and configured to be inserted into a receptacle as will be described in greater detail below. The contact 104A and the insulator 106A may be inserted into a ground body 108A which may be made of a conductive material or materials, such as phosphor bronze and/or selective gold- or nickel-plating, and the like.
Like the contact sub-assembly 102A, the contact sub-assembly 102B also comprises a combination of a contact 104B that is located inside of an insulator 106B, both of which are located inside of a ground body 108B. However, in contrast to the contact sub-assembly 102A, the length of the contact 104B that connects to the PCB may be shorter than the contact 104A in order to adjust for the location of the contact sub-assembly 102A on the top row of the housing 110 and the contact sub-assembly 102B on the bottom row of the housing 110. In other words, in order for all of the contact portions 102A and 102B to extend substantially equally in length into the PCB (not shown), the contacts associated with each row may be different lengths because the bottom row of the housing 110 may be located closer to the PCB than the top row.
A plurality of the contact sub-assemblies 102A or 102B may be secured together in a housing 110. The housing 110 may be made, for example, from 30% glassed-filled polybutylene terephthalate (PBT), which is a thermoplastic polymer. The housing 110 may include a plurality of holes 114 preferably in a grid-like pattern for receiving the individual contact sub-assemblies 102A or 102B. The contact sub-assemblies 102A and 102B extend through the holes 114 to define a plug interface 120 on a first end of the housing 110 and a PCB interface 122 on the other end. The housing 110 may also include one or more guide pin holes 116 for receiving stainless steel guide pins 112. The guide pins 112 may be used to securely physically connect the plug assembly 100 to other receptacle assemblies or high-float option bullet adapters, which will be described in greater detail below.
The plug housing 110 may also include various features for securing to a high float bullet adapter or receptacle. For example, one or more nubs 124 may protrude from the top portion of the housing 110 and be made of the same material as the housing 110 (e.g., plastic). Similarly, one or more nubs 126 may be located on opposite sides of the housing 110 that are different from the plug interface 120 and the PCB interface 122. The nubs 124 and 126 may be received by a corresponding nub loop located on a high float bullet adapter, which will be described in greater detail with respect to
Turning to
Guide pin holes 224 may be located in the housing 210 for receiving guide pins (not shown in
Each individual bullet sub-assembly 300 is configured such that the insulator 304 preferably extends beyond the contact 302 and ground body 306 and thus protrudes from its interface at its end 308. The end 308 preferably has a lead-in geometry, such as a substantially square-based pyramid, or “dart”, shape. This geometry for the insulator portion 304 is preferably narrow to allow for ganging closer together a plurality of the individual bullet sub-assemblies 300 in a more compact housing. However, it is appreciated that other lead-in geometries may be used for the insulator portion 304 without departing from the scope of the subject matter described herein.
The high float bullet adapter housing 402 may include a plurality of holes 404 preferably in a grid-like pattern for receiving the high-float bullet sub-assemblies 300. The high-float bullet sub-assemblies 300 extend through the holes 404 to connect the plug 100 to the receptacle 200. The high float bullet adapter housing 402 may also include one or guide pin more holes 406 for receiving guide pins 112. The guide pins 112 may be used to securely physically connect the plug assembly 100 to the high-float option bullet adapter 400. The guide pins 112 may be formed of stainless steel, for example.
The high float bullet adapter housing 402 may further include nub loops 408 and 410 that extend beyond the face of the holes 404 and correspond to the shape of the nubs 124 and 126 located on the plug 100 for receipt of the same. The nub loops 408 and 410 physically secure the high float bullet adapter housing 402 with the plug housing 110 in a snapping engagement. However, it is appreciated that the attachment for housings 110 and 402 other than the nubs 124-126 and the nub loops 408-410 shown in
Also similar to the straight receptacle configuration 200, the individual receptacle sub-assemblies 502 may be secured together in a housing 510. For example, the housing 510 may include a plurality of holes 512 preferably in a grid-like pattern for receiving the individual receptacle sub-assemblies 502 and the high-float bullet sub-assemblies 300, and/or the plug interface 120 of the plug 100. The receptacle sub-assemblies 502 extend through the holes 512 to connect the plug 100 to the receptacle 200. The housing 510 may also include one or guide pin more holes 514 for receiving the guide pins 112. The guide pins 112 may be used to securely physically connect the receptacle assembly 500 to the high-float option bullet adapter 400. The housing 510 may be formed of plastic and may include additional holes for receiving one or more guide pins for maintaining alignment between connectors. In contrast to the straight receptacle 200, the housing 510 of the right angle receptacle 500 maybe larger than the housing 210 in order to accommodate the increased length associated with the receptacle sub-assemblies 502.
In the connector assembly configuration shown in
As described above, the high float bullet adapter 400 includes a plurality of high-float bullet sub-assemblies 300 for interfacing between the male portion of the plug 100 and the female portion of the receptacle 500, where each high-float bullet sub-assembly 300 comprises the conductor 302, the insulator 304, and the ground body 306. Because the high float bullet adapter 400 can be designed to be compatible with the configurations of the plug 100 and the receptacle 500, the high float bullet adapter 400 may be inserted or removed from between the plug assembly 100 and the receptacle assembly 500 in order to easily and quickly convert between high float and low float configurations.
The shape of the high-float bullet sub-assemblies 300 allows for increased axial and radial movement (i.e. float) between the plug and receptacle assemblies and a more compact footprint while maintaining a secure electrical connection. Specifically, the shape of the high-float bullet sub-assemblies 300 includes the insulator 304 of each individual bullet sub-assembly 300 preferably extending beyond the contact 302 and thus protruding from its interface with a substantially square-based pyramid, or “dart”, shaped lead-in geometry. This geometry for the insulator portion 304 is smaller than conventional lead-in geometries and allows for ganging closer together a plurality of the individual bullet sub-assemblies 300 in a more compact housing while increasing the degree of float. Each of these advantages over the prior art may be useful in a variety of applications, but particularly in RF connector applications such as wireless telecommunications applications, including WiFi, PCS, radio, computer networks, test instruments, and antenna devices.
The outer ground body 810, typically made of metal, which surrounds the insulator portion 802 may include four sidewalls 812 corresponding to each side of the insulator portion 802. The tips 814 of the sidewalls 812 may be curved inward toward the center of the bullet 800 and may be located in between the corners 804 of the dielectric portion 802. The outer ground body 810 may be composed as one-piece or multiple pieces secured together with a dovetail joint 816, for example, or any other suitable means. The base 822 of the ground body 810 may further include tail portions 818 on each side in the embodiment shown. Tail portions 818 are preferably curved outwardly, as seen in
As seen in
As seen in
Referring to
As seen in
The insulator 1304 is received in the conductive shell 1302 and generally includes an engagement end 1330 or engaging the shell 1302, an interface end 1332 that is opposite the engagement end 1330 that extends partially through the first end 1310 of the shell 102, and a reduced diameter middle portion 1334 between the engagement and interface ends 1330 and 1332. A longitudinal inner bore 1336 extends through the insulator 1304, as seen in
The interface end 1332 has a lead-in tip portion 1338 that extends outside of the first end 1310 of shell 1302 for facilitating mating with a connector. The lead-in tip portion 1338 has a tapered outer surface 1340 terminating in an end face surface 1342. A shoulder 1344 may be provided at the interface end 1332 of the insulator 1304 that is remote from the end face surface 1342. The shoulder 1344 preferably provides an outer diameter D (
The engagement end 1330 of the insulator 1304 has an outer diameter than is preferably substantially the same as the inner diameter of the conductive shell 1302, as seen in
The reduced diameter middle portion 1334 of the insulator 1304 has a width significantly less than the engagement end 1330 and interface end 1332, thereby defining an open annular area or space 1335 between the reduced diameter middle portion 1334 and the inner surface of the conductive shell 1302. The annular space 1335 allows for proper impedance through the adapter.
The inner contact 1306 is received in the inner bore 1336 of the insulator 1304 generally along the central longitudinal axis of the adapter 1300. The inner contact 1306 generally includes a body 1360 that has first and second socket openings 1362 and 1364 at either end 1366 and 1368 thereof. The socket openings 1362 and 1364 are adapted to accept mating pin contacts. Each end of the body 1360 may also include slots 1370 and 1372, respectively, to provide flexibility to the sockets 1362 and 1364. One end 1368 of the inner contact 1306 extends through the engagement end 1330 of the insulator 1304. That end 1368 may include a flared portion 1374. Because there is no insulator on this side of the adapter, the flared portion 1374 provides a similar function as inner stopping shoulder 1348, which helps ensure the mating contact is guided into proper mating condition.
The float adapter 1300 of the present invention is preferably assembled by inserting the insulator 1304 into the conductive shell 1302 through its first end 1310 and inserting the inner contact 1306 through the second end 1312 of the conductive body 1302 and into the inner bore 1336 of the insulator 1306. The insulator 1304 may be inserted into the conductive shell 1302 until the groove 1350 of the insulator 1304 and the corresponding flange 1352 of the conductive shell 1302 snap together. The inner contact 1306 is preferably inserted into the internal bore 1336 of the insulator 104 until the contact 1306 abuts the inner stopping shoulder 1348 of the insulator 104.
The body of the connector 1400 includes two cavities 1410 that each accepts the second end 1312 of the adapter's shell 1302. Each cavity 1410 includes a conductive shield or bushing 1412. Each conductive shield 1412 preferably includes an annular groove 1414 that couples with the annular lip 1322 of each adapter shell's second end 1312. Each cavity 1410 includes a widened area 1416 that facilitates radial float movement of the adapters 1300.
The insulator 1504 generally includes an engagement end 1530 for engaging the shell 1502 and the retaining sleeve 1524, an opposite interface end 1532 that extends partially through the second end 1512 of the shell 1502, and a reduced diameter middle portion 1534 therebetween that creates an annular space 1535 between the insulator 1504 and the inner surface of the shell 1502, as seen in
The interface end 1532 has a lead-in tip portion 1538 that extends outside of the second end 1512 of shell 1502 for facilitating mating with a connector. The lead-in tip portion 1538 has a tapered outer surface 1540 terminating in an end face surface 1542. A shoulder 1544 at the interface end 1532 of the insulator 1504 that is remote from the end face surface 1542 provides an outer diameter of the insulator 1504 that is larger than the inner diameter of the shell 1502. The end face surface 1542 of the insulator's interface end 1532 includes an interface opening 1546 in communication with the inner bore 1536. The interface opening 1546 may have an inner surface that tapers inwardly toward the inner bore 1536 to facilitate acceptance of the contact. Also at the interface opening 1546 of the interface end 1532 is an inner stopping shoulder 1548.
The engagement end 1530 of the insulator 1504 has an outer diameter than is preferably substantially the same as the inner diameter of the conductive shell 1502, as seen in
The retaining sleeve 1524 has a ring shaped body 1554 sized and adapted to fit over the shell 1502. The engagement member or tab 1552 extends inwardly from the ring body 1554 such that when the sleeve 1524 is positioned on the shell 1502, the tab 1552 extends through a complementary slot 1556 (
The inner contact 1506 is received in the inner bore 1536 of the insulator 1504 generally along the central longitudinal axis of the adapter 1500. The inner contact 1506 generally includes a body 1560 that has first and second socket openings 1562 and 1564 at either end thereof, as seen in
Insulators 1604a and 1604b are substantially identical and each generally includes an engagement end 1630 for engaging the shell 1602 and the retaining sleeve 1624, an opposite interface end 1632 that extends partially through the ends 1610 and 1612, respectively, of the shell 1602, and a reduced diameter middle portion 1634 therebetween. An annular space 1635 is defined between each insulator 1604a and 1604b and the inner surface of the shell 1602, as seen in
Like the insulator 1504 of the adapter 1500, the interface end 1632 of each insulator 1604a and 1604b has a lead-in tip portion 1638 that extends outside of the respective ends 1610 and 1612 of shell 1602 for facilitating mating with a connector. The lead-in tip portion 1638 of each insulator 1604a and 1604b has a tapered outer surface 1640 terminating in an end face surface 1642, as seen in
Each engagement end 1630 of each insulator 1604a and 1604b has an outer diameter than is preferably substantially the same as the inner diameter of the conductive shell 1602, as seen in
The retaining sleeve 1624 has a body 1654 sized and adapted to fit over the shell 1602 to form a cylindrical shape. A dovetail feature 1668 may be provided to keep the body 1654 in the cylindrical shape around the shell 1602. The body 1654 includes first and second engagement members 1652a and 1652b for engaging the insulators 1604a and 1604b. In a preferred embodiment, the first and second engagement members 1652a and 1652b are tabs extending from an inner surface of the body 1654, as seen in
The inner contact 1606 is received in the inner bores 1636 of the insulators 1604a and 1604b generally along the central longitudinal axis of the adapter 1600. The inner contact 1606 generally includes a body 1660 that has first and second socket openings 1662 and 1664 at either end thereof. The first socket opening 1662 is seated in the interface end 1632 of the first insulator 1604a and the second socket opening 1664 is seated in the interface end 1632 of the second insulator 1604b.
The following is an exemplary method of manufacturing and assembling the adapters of the present invention, for example adapters 1500 and 1600. Initially, the shells, e.g. shells 1502 and 1602, may be formed by stamping in accordance with a preferred method of the present invention. More specifically, the shell may be formed by stamping a piece from a metal sheet and then rolling that piece to form a cylindrical body which becomes the shell. A dove tail feature, such as dove tail 1568 (
Between the step of initially stamping the metal piece and rolling the same, the piece may be cut at its ends to form the longitudinal slots which will form fingers, e.g. fingers 1514 and 1614, at the ends of the shell. Subsequent to cutting the slots in the metal piece, a groove may be impressed into those fingers which will form a lip, e.g. lips 1520, 1522, 1620, and 1622, at the ends of the cylindrical body when rolled to form the shell. Additionally, one more slots, such as slots 1556, 1656a and 1656b, may be cut into the stamped metal piece before rolling it into the cylindrical body form.
Once the metal piece is stamped and rolled to form the shell, the adapter may be assembled, as illustrated in
Once the shell 1602, insulators 1604a and 1604b, and inner contact 1606 are assembled, the retainer sleeve 1624 can then be coupled around the shell 1602 to secure the assembly, as shown in
While particular embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims. For example, although the connectors may be shown as a right angle connector, the connectors may any type of connector, including a straight connector, and vice versa.
Barthelmes, Owen R., Hoyack, Michael A., Zhu, Juliver, He, Harry, Qin, Leo
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